The Fives FCB sustainable cement plant

Fives

FICEM APCAC – XXIX Congreso Técnico – Costa Rica - San José – 05/09/2012

Driving Progress

The Fives FCBsustainable

cement plant

FICEM APCAC – 05/09/2012 2

The Fives FCB sustainable plant in figures

Less than 500 mg/Nm3 of NOx (equivalent NO2 dry @ 10%O2) at stack

Up to 70% of AFR substitution at precalciner (on thermal load)

Thanks to the combination of the Fives FCB precalciner & Fives Pillard burner

Less than 80 kWh/t of cement

High clinker substitution factor

Thanks to the Fives FCB Horomill & Fives FCB TSVTM

Zero water consumption

Thanks to the combination of the Fives FCB Horomill & common filter

A combination of advanced proven technologies

Low emissions

Low power consumption

High alternative fuels substitution


High clinker substitution

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The Fives FCB Zero-NOx Precalciner: an advanced technology

The Concept: a real COMBUSTION CHAMBER

Downward High-Performance Burner:• Creating a Hot Spot• For successful ignition & efficient

combustion• Staged Combustion in reducing conditions• Zero-NOx

Air and Meal injection:• Through a ring without cycloning• Creating a meal curtain• Protection of lining• Progressive and efficient mixing

Designed to burn difficult solid fuels and a high rate of alternative solid fuels with Zero-NOx emission

Low-NOx burner with central channel for ASF

Meal feed

Direct flow

Ring-shaped injection

Distribution chamber

FICEM APCAC – 05/09/2012

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The Fives FCB Zero-NOx Precalciner: an advanced technology

Hot spot for complete burn-out

Centered flame

Protected lining


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Combined with the Fives Pillard Precalciner burner

A low-NOx high performance burner (in Hoang Mai/Vietnam cement plant)


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The Fives FCB Zero-NOx Precalciner: a proven technology

Hoang Mai (Vietnam)• 100% low volatile anthracite coal (< 8%)• Ø 5.6 m – capacity 4,000 t/d• Residence time: 4.5 seconds

Umm Bab (Qatar)• Natural gas• Ø 5.2 m – capacity 5,000 t/d• Residence time: 3 seconds

Holcim-Apasco (Mexico)• 100% petcoke & ASF• Ø 5.6 m – capacity 3,500 t/d• Residence time: 5 seconds


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The Fives FCB Horomill: an advanced technology


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The Fives FCB Horomill: an advanced technology


Grinding layer centrifugation

Control of grinding actions

Control of material advance

Simple concept

Continuous adaptations

32+4

1+2

2+2

2

2

2

2

3

2

Twin cement grindingCement grinding

Raw grinding

Plants with both rawand cement grinding

Slag or mineral grindingTwin slag grindingNot erected

56 HOROMILLS

Horomill®: a worldwide proven technology

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More than 1.5 millions hours of operation



Low emissions





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The Fives FCB sustainable plantLow emissions

Cartago (Holcim Costa Rica) NOx Emissions hourly average in mg/Nm3 @ 10%O2 dry

Less than500 mg/Nm3

NOx atpreheaterexhaust

No need ofSNCR systemin most cases

HOURLY NOx EMISSIONS AT CHIMNEY STACK

100

150

200

250

300

350

400

450

500

550

00:00 08:00 16:00 00:00 08:00 16:00 00:00 08:00 16:00 00:00 08:00 16:00 00:00 08:00 16:00 00:00

TOTAL NOx (mg/Nm³ @ 10%O2, dry fumes) on 15th to 19th October 2007

… and less than 100 ppm CO with 100% petcoke

mg/Nm³



Low emissions





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The Fives FCB sustainable plantHigh alternative fuels substitution

Cartago (Holcim Costa Rica) : up to 70% coarse ASF (thermal load) can be fed directly in the precalciner burner (ASF made of rubber, plastics and papers)

ppm kg/h


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The Fives FCB sustainable plantHigh alternative fuels substitution

Alternative Fuels

Hermosillo (Holcim Apasco)

A quick and efficient ignition

A good burn-out & low CO

50% of shredded tyres (thermal load)



Low emissions





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The Fives FCB sustainable plantLow power consumption

Horomill® 3800 CEM II/B-P Slag /CEM III/A/B

CEM I /CEM II/A-L CEM I

Blaine 3 600 4 000 3000 / 3500 4 000Capacity t/h 130 67 115 72Horomill® kW 2 047 1 880 1 900 1 880Horomill® kWh/t 15,7 28,1 16,5 26,1TSV™ kWh/t 0,5 1,5 0,5 1,5Elevator kWh/t 0,8 1,3 0,9 1,3Fan kWh/t 4,2 8,5 3,7 6,7Total kWh/t 21,3 39,4 21,6 35,5

Ball Mill CEM II/B-P Slag /CEM III/A/B

CEM I /CEM II/A-L CEM I

Blaine 3 800 4 000 3200 / 3700 4 200Capacity t/h 121 53 115 78Ball mill kW 3 600 3 600 3 600 3 600Ball mill kWh/t 29,8 67,9 31,3 46,2TSV™ kWh/t 0,3 0,6 0,2 0,6Elevator kWh/t 0,4 0,8 0,4 0,6Fan kWh/t 3,3 6,3 2,6 4,1Total kWh/t 33,7 75,7 34,5 51,4

Savings kWh/t 12,4 36,3 13,0 15,937% 48% 38% 31%

Large energy savings compared to the ball mill …


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Horomill® : the lowest energy consumption

… but also substantial energy savings compared with the vertical mill

Absorbed Power Vertical mill Horomill® Vertical mill Horomill®

Mill 1 820 1 820 1 850 1 850

Separator 60 30 135 55

Elevator 30 160 30 105

Fan 1 880 770 930 450

Auxiliaries 60 50 60 50

Total abs. Power kW 3 850 2 830 3 005 2 510

Specific energy kWh/t 16.7 12.3 26.1 21.8

Savings (%) -26.5% -16.5%

Raw meal grinding Cement grinding

230 t/h - 12% R90µ 115 t/h CEM II A/P - 3900 Blaine


which can represent more than 1 MUSD in annual operation cost

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The Fives FCB sustainable plantLow power consumption

Cement plant consumption: 80 kWh/ton of cement

Example of cement plants fully equipped with Fives FCB Horomill

Tepetzingo (Mexico): 2 lines with 1 Horomill®

for raw grinding and 1 Horomill® for cement

Cerritos (Mexico): 2 lines with 1 Horomill®


Apazapan (Mexico):1 line with 1 Horomill®


Typical cement produced: CEM I / CEM II-A/P @ 4200 Blaine



Low emissions





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The Fives FCB sustainable plantHigh clinker substitution: stability & flexibility

the Horomill® installed at Lafarge Karsdorf (Germany) produces up to 7 different recipes


Trino 2SMA 1Cimentas 1Darica 3Karsdorf 7Tepetzingo 3 & 4 2Cizkovice 2Tepetzingo 1 & 2 1RCC 1Denizli 3 & 4 3Maxit 1Confidential 1 1Confidential 2 1Konya 1

7 2 4 2 2 1 1 1 1 1 1 2 1


Low emissions





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The Fives FCB sustainable plantZero water consumption: the Fives FCB common filter


Example of zero water burning line equipped with Fives FCB common filter: Holcim Hermosillo

Air/Air Heat exchanger

Mixing chamberwith dilution

Common stack

Common filterwith PTFE bagsHE cyclones

Booster fan

Preheater downcomerwithout water injection

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The Fives FCB sustainable plantZero water consumption: the Fives FCB Horomill


Example of zero water cement grinding equipped with Fives FCB Horomill: Holcim Hermosillo

No need of water for grinding

Centrifugation of the layer

procuring grinding stability

No need of water thermal balance

External recirculation

with cooling in the classifier loop

FICEM APCAC – 05/09/2012 25

The Fives FCB sustainable plant in figures

Less than 500 mg/Nm3 of NOx (equivalent NO2 dry @ 10%O2) at stack

Up to 70% of AFR substitution at precalciner (on thermal load)

Thanks to the combination of the Fives FCB precalciner & Fives Pillard burner

Less than 80 kWh/t of cement

High clinker substitution factor

Thanks to the Fives FCB Horomill & Fives FCB TSVTM


Thanks to the combination of the Fives FCB Horomill & common filter

Thank you for your attention

The Fives FCB sustainable cement plant

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